Packaging for lighting equipment

ABSTRACT

Packaging and delivery systems and methods for lighting devices such as streetlights. One embodiment of the invention includes a lighting device packaging and delivery system for a partially or completely preassembled and pre-wired luminaire and pole. The packaging and methods allow the unit to be shipped and installed with very little or no assembly required. The unit, or multi-pack of units, may be packaged with all of the required components, such as the photo control and lamp, already installed.

FIELD OF THE INVENTION

The present invention relates to packaging, and particularly, relates topackaging and delivery of large lighting devices and equipment.

BACKGROUND OF THE INVENTION

Outdoor lighting devices, such as streetlights, are commonly used to aidautomobile and pedestrian safety at night and in unfriendly weatherconditions. A streetlight is typically a raised lamp near the edge of astreet that is turned on or lighted at a certain time each night.Streetlights may also have light-sensitive photocells that turn them onand off automatically, for example, on at dusk or in bad weather and offat sunrise. Streetlights typically include, or attach to, a pole orother structure to raise them above the ground. Such poles can havelengths exceeding 20 feet. In many cases, the light or lights at the topof a streetlight pole are connected to an electricity source throughelectrical wiring that runs down through the pole.

Lighting devices often require a significant amount of assembly,installation, and setup after delivery. Assembling and electricallyconnecting components can be time-consuming and may require theassistance of an expert, technician, or electrician. The need forelectrical expertise and assembly is even more common and burdensome forlarger lighting devices, such as streetlights, which are usually shippedin a partially unassembled manner because of their size or shape. Whenthe pole, lamps, and other components of a streetlight are shipped ordelivered in unassembled form, a significant amount of time and effortmay be required to properly assemble and electrically connect thevarious components. In some cases, this work must be done at the top ofa pole high above ground level, requiring additional equipment such asladders and high-reach trucks.

The components of large lighting devices such as streetlights arecommonly ordered separately from one another. Past ordering methods haveinvolved having a purchaser place individual purchase orders for each ofa lamp, a control, a luminaire, a pole, and wiring. The separateordering of the lighting device's components typically requiresadditional effort in order to coordinate shipment schedules such thatthe materials will arrive at the same time. Additionally, there is arisk that one or more of the components will not arrive at its scheduleddelivery time, delaying the installation of the lighting device.

SUMMARY OF THE INVENTION

One embodiment of the present invention includes a package for alighting device that includes an encasing structure that surrounds atleast a portion of a luminaire of the lighting device. An aperture inthe encasing structure is configured to allow a pole connected to theluminaire to extend from the encasing structure. Another embodiment ofthe present invention includes a method of packaging a lighting devicethat includes encasing the luminaire of the lighting device with anencasing structure of a package such that a pole of the lighting deviceextends through an aperture. A third embodiment of the present inventionincludes a method of selling a lighting device that includes offeringfor sale a lighting device, which includes a luminaire preassembled to apole, under a single item code, accepting an order for the single itemcode for delivery to a delivery location, and shipping the lightingdevice to the delivery location.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an exemplary packaging for a lighting device in accordancewith an embodiment of the present invention.

FIG. 2 shows the exemplary packaging for the lighting device of FIG. 1with the first and second portions assembled around the luminaire.

FIG. 3 shows an exemplary bundle of packaging for lighting devices inaccordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Introduction

One embodiment of the invention includes a lighting device packaging anddelivery system for a partially or completely preassembled and pre-wiredluminaire and pole. The packaging allows the unit to be shipped andinstalled with very little or no assembly required. The unit, ormulti-pack/bundle of units, may arrive at the destination with all ofthe required components, such as the photocontrol and lamp, alreadyinstalled. Upon arrival, the installer will remove the packagingprotecting the luminaire and possibly some wrapping protecting a pole,orient the fixture in the proper direction if needed, and lower it intothe prepared hole for the direct burial pole. The supply wiring ispulled through the proper openings in the pole base, the wiring isconnected, and pole installation is completed. In some embodiments, thepackaging is designed to interlock with other units of the same type toform a multi-pack or bundle. For example, the packaging may have one ormore recesses to allow adjacent luminaires or poles of other lightingdevices to be secured.

Exemplary Embodiment of a Packaged Lighting Device

FIGS. 1 and 2 show a packaged lighting device 100. An encasing structure101 having a first portion 102 and second portion 104 is used topackage, ship, deliver, store, and/or display lighting device 106. Theencasing structure 101 may have a rectangular outer shape, a squareouter shape, or any other suitable shape, and may be composed of twoseparable portions 102, 104, as shown, or of any suitable number ofcomponents or pieces. As shown, in this embodiment, the two portions102, 104 of the encasing structure 101 encase primarily the luminaire108 of the lighting device 106, and allow the pole 110 to extend outwardfrom the packaging. Note that the term “pole” is not limited to anyparticular shape or size. Any suitable extending structure may be used.In some cases, the lighting device 106 will be a streetlight with a pole110 having a length greater than 5 feet, 8 feet, 10 feet, 12 feet, 15feet, 20 feet, or more.

Also note that although this embodiment describes an encasing structure101 having two portions 102, 104, in other embodiments, the encasingstructure 101 may consist of only one portion or more than two portionsof different or the same shapes, sizes, materials, and configurations.Different portions of a multi-portion package may be secured to oneanother, the luminaire, and/or other portions of the lighting device byconnectors, through an interference fit, a surrounding structure orencasement, and/or any other suitable means. Alternatively, the portionsmay not be secured together or to other structure in some embodiments.

In the embodiment of FIGS. 1 and 2, the inside 112 of each of theportions 102, 104 of the encasing structure 101 is configured or shapedso that, once encased, the luminaire 108 of the lighting device 106 willbe partially or completely surrounded by protective packaging materials.The invention is not limited to any particular size, shape,configuration, material, type, or style of packaging or protection. Theinside 112 of each of the portions 102, 104 of the encasing structure101 may be made of any suitable material and shaped to generally matchor conform to the outer shape of the luminaire 108.

The first portion 102 and the second portion 104 of the encasingstructure 101 of the package are also each configured to form respectivesemi-circles 114 a, 114 b on one end. The respective semi-circles 114 a,114 b come together to form a circular aperture 116 when the package isinstalled around the luminaire 108 of the lighting device 106, as shownin FIG. 2. The pole 110 extends through aperture 116. In someembodiments, the aperture will have a shape and size similar to theshape and size of a cross section of the pole. In other embodiments, theaperture will have a different shape and size. For example, the aperturemay be larger than the cross section of the pole of a lighting device.

The portions 102, 104 of the encasing structure 101 may only partiallysurround the luminaire 108, and may surround a portion or all of thepole 110. As explained in greater detail below, the portions 102, 104may also be configured such that the package can be secured, connected,or attached to another package or lighting device component such as apole. The encasing structure configuration, whether including one ormore portions, may include one or more package recesses 118,projections, and/or pole recesses 120 a, 120 b, 120 c, 120 d, that workalone or in combination with other components to secure, attach,connect, or otherwise hold packaging or a lighting device.

One embodiment of the present invention is a method of packaging alighting device comprising encasing a luminaire of the lighting devicewith portions of an encasing structure of a package, wherein a pole ofthe lighting device extends through an aperture.

Exemplary Embodiment of Multi-Packaged Lighting Devices

Interlocking Package to Package

FIG. 3 shows a bundle 300 or multi-pack of eight packaged lightingdevices 310, 320, 330, 340, 350, 360, 370, 380. A first set of packagedlighting devices 310, 320, 330, 340 have packaged luminaires on a firstpallet 402, while a second set of the packaged lighting devices 350,360, 370, 380 have packaged luminaires on a second pallet 404. Thepackaging of the first set of packaged lighting devices 310, 320, 330,340 on one end of the bundle may interact with one another such thatthey are secured, connected, or otherwise held together.

Referring again to FIGS. 1 and 2, an individual package encasingstructure 101 may include one or more recesses 118 and one or moreprojections for securing, connecting, or attaching to a neighboringpackage in a lighting device bundle.

Referring now to FIG. 3, package 310 may be connected to package 320 bythe interaction of a recess and projection (not shown). Accordingly, insome embodiments, the encasing structure of a package may also includean outer surface configured to interlock with a corresponding recess inthe outer surface of the encasing structure of another lighting devicepackage. Different packages of a bundle 300 may be secured to oneanother by a connector, interference fit, surrounding structure,encasement, or shrink wrap, and/or any other suitable means.Alternatively, the packages may not be secured together.

Referring again to FIGS. 1 and 2, one embodiment of the presentinvention is a method of packaging a lighting device. The methodcomprises encasing a luminaire 108 of the lighting device 106 withencasing structure 101 of a package, wherein a pole 110 of the lightingdevice 106 extends through an aperture 116 in encasing structure 101,and interlocking encasing portions 102, 104 of the package with theencasing portions of a second lighting device package by fitting aprojection on an outer surface of one of encasing portions 102, 104 witha corresponding recess in the outer surface of an encasing portion ofthe second lighting device package.

Interlocking Pole to Package

Referring now to FIG. 3, the two ends of the bundle 300 of lightingdevice packages 310, 320, 330, 340, 350, 360, 370, 380 may be connected,attached, or otherwise secured through an interaction between the polesof the devices on one end with the packages on the other end. Therespective poles 312, 322, 332, 342 of the first set of packagedlighting devices 310, 320, 330, 340 extend and interact with the secondset of packaged lighting devices 350, 360, 370, 380. In a similarmanner, the respective poles 352, 362, 372, 382 of the second set ofpackaged lighting devices 350, 360, 370, 380 extend and interact withthe first set of packaged lighting devices 310, 320, 330, 340.Accordingly, the two sets of packaged luminaires interact to form abundle 300 or multi-pack of packaged luminaire devices 310, 320, 330,340, 350, 360, 370, 380 that can be set on two pallets 402, 404.

Referring now to FIGS. 1 and 2, encasing portions 102, 104 may beconfigured to allow for the pole to package interactions illustrated inFIG. 3. In FIGS. 1 and 2, pole recesses 120 a, 120 b, 120 c, 120 d areused to hold or secure the end of poles in a bundle. In this embodiment,the first portion 102 has a first pole recess 120 a and a second polerecess 120 b, and the second portion 104 has a third pole recess 120 cand a fourth pole recess 120 d. The pole recesses 120 a, 120 b, 120 c,120 d compliment each other when the portions 102, 104 are installed tosurround a lighting device 106. Specifically, the first recess 102 a onthe first portion 102 and the third recess 120 c on the second portion104 cooperate to form a semicircle. Likewise the second recess 102 b onthe first portion 102 and the fourth recess 120 d on the second portion104 cooperate to form a semi-circle. The shape formed is not limited toa semi-circle. Any suitable shape or size may be used to form a recessthat is capable of securing or otherwise interacting with the end of thepole of an opposite facing lighting device in a bundle.

The pole recesses 120 a, 120 b, 120 c, 120 d may also interact with polerecesses of other packaged lighting devices in a bundle. Twosemi-circles could be placed adjacent one another to form a whole circlein which the pole of an opposite facing lighting device may be secured.Accordingly, in one embodiment, the package includes a pole recesspositioned on the outer surface of the encasing portion such that itinteracts with a pole recess on a package of another lighting device tosecure the pole of yet another the lighting device.

Referring again to FIGS. 1 and 2, one embodiment of the presentinvention is a method of packaging a lighting device 106 comprisingencasing a luminaire 108 of the lighting device 106 with portions 102,104 of an encasing structure 101 of a package, wherein a pole 110 of thelighting device 106 extends through an aperture 116 in the portions 102,104, and securing the pole of a second lighting device with a polerecess on an outer surface of the portions 102, 104.

Another embodiment includes a method of packaging a lighting device 106comprising encasing a luminaire 108 of the lighting device 106 with anencasing portion 102, 104 of an encasing structure 101 a package,wherein a pole 110 of the lighting device 106 extends through anaperture 116 in the portions 102, 104, and interlocking the package witha plurality of other lighting device packages to form a bundle 300 ofpackaged lighting devices. As described above, in one embodiment, thebundle 300 of lighting devices forms a structure having encasedluminaires on two ends and light fixture poles in the center. In anotherembodiment, each of the encased luminaires at one end of the bundle isconnected to a pole secured by the encasing portion of the luminaires atthe other end of the bundle. In yet another embodiment, the two ends ofthe bundle are placed on separate shipping pallets.

Yet another embodiment includes a method of packaging a lighting devicethat involves encasing the luminaire, but not the pole, with a package,and interlocking the package with a plurality of other lighting devicepackages to form a bundle. The bundle of packaged lighting devices maybe then shipped, delivered, displayed, and/or stored until theindividually packaged lighting devices are removed from the bundle.

Exemplary Embodiment of a Method of Selling a Lighting Device

Another embodiment of this invention includes a method of selling alighting device that includes offering a lighting device for sale undera single item code wherein the lighting device includes a luminairepreassembled to a pole, accepting an order for the single item code fordelivery to a delivery location, and shipping the lighting device to thedelivery location. In one embodiment, the lighting device item code willrelate to a lighting device having a control unit preassembled with aluminaire and a pole and, in another embodiment, it will identify alighting device that is fully assembled. It is not necessary to use anitem code in some embodiments of this invention. In some embodiments,the order for the lighting device will be made by reference to a tradename or other identifying information for the lighting device.

Advantages

Some embodiments of the of the present invention may save a lightingdevice customer or installer a large amount of time and expense byavoiding or reducing the need to assemble the components of a luminairerequired to make the unit operable (i.e., the lamp, pole, photocontrol,etc.). In some embodiments, the luminaire may be shipped and deliveredin a preassembled form, such that the pole, lamp, photocontrol, andother components are preassembled, connected, and/or wired together.Accordingly, in many embodiments, a technician or electrician will notbe required to wire the lamp, pole, and other components. Moreover, inmany embodiments, equipment such as a ladder or bucket truck will not berequired to install the luminaire at the top of a pole, since theelectrical connections between the lamp, pole, and other components maybe done prior to shipment and installation of the luminaire.

Another advantage to some embodiments, is that the same lighting devicepackage may be used to ship luminaires individually and luminairespreassembled with other lighting device components such as a pole. Inthese embodiments, the shape of the packaging encases primarily theluminaire but allows for a pole to extend outwardly. If no pole isattached, the package simply encases the luminaire.

ALTERNATIVE EMBODIMENTS

The foregoing description of the exemplary embodiments of the inventionhas been presented only for the purposes of illustration and descriptionand is not intended to be exhaustive or to limit the invention to theprecise forms disclosed. Many modifications and variations are possiblein light of the above teaching. The embodiments were chosen anddescribed in order to explain the principles of the invention and theirpractical application so as to enable others skilled in the art toutilize the invention and various embodiments and with variousmodifications as are suited to the particular use contemplated.Alternative embodiments will become apparent to those skilled in the artto which the present invention pertains without departing from itsspirit and scope. For example, embodiments of the invention may includeencasing structures having one or more separable portions, one or moresemi-attached portions, a single portion, separate portions made ofdifferent materials, recyclable materials, materials with holes, etc.Accordingly, the scope of the present invention is defined by theappended claims rather than the foregoing description and the exemplaryembodiments described therein.

1. A package for a lighting device comprising: an encasing structure that surrounds at least a portion of a luminaire of the lighting device; and an aperture in the encasing structure through which a pole connected to the luminaire extends; wherein an outer surface of the encasing structure includes a projection for connecting to a recess in an outer surface of another lighting device package.
 2. The package of claim 1, wherein the encasing structure has a rectangular outer shape.
 3. The package of claim 1, wherein the encasing structure has a square outer shape.
 4. The package of claim 1, wherein the encasing structure comprises two separable portions.
 5. The package of claim 1, wherein the encasing structure completely surrounds the luminaire.
 6. The package of claim 1, wherein the aperture is larger than the cross section of the pole.
 7. A package for a lighting device comprising: an encasing structure that surrounds at least a portion of a luminaire of the lighting device; and an aperture in the encasing structure through which a pole connected to the luminaire extends; wherein the encasing structure includes a pole recess for securing a pole of another lighting device.
 8. The package of claim 7, wherein the pole recess is positioned on the outer surface of the encasing portion such that it interacts with a pole recess on a package of a third lighting device to secure the pole of the second lighting device.
 9. The package of claim 7, wherein the encasing structure has a rectangular outer shape.
 10. The package of claim 7, wherein the encasing structure has a square outer shape.
 11. The package of claim 7, wherein the encasing structure comprises two separable portions.
 12. The package of claim 7, wherein the encasing structure completely surrounds the luminaire.
 13. The package of claim 7, wherein the aperture is larger than the cross section of the pole.
 14. A method of packaging a lighting device comprising: encasing a luminaire of the lighting device with an encasing structure of a package, wherein a pole of the lighting device extends through an aperture in the encasing structure; and interlocking the encasing structure of the package with a second encasing structure of a second lighting device package by fitting a projection on an outer surface of the first encasing structure with a corresponding recess in the outer surface of the second encasing structure.
 15. A method of packaging a lighting device comprising: encasing a luminaire of the lighting device with an encasing structure of a package, wherein a pole of the lighting device extends through an aperture in the encasing structure; and securing a pole of a second lighting device with a pole recess on the encasing structure.
 16. A method of packaging a lighting device comprising: encasing a luminaire of the lighting device with an encasing structure of a package, wherein a pole of the lighting device extends through an aperture in the encasing structure; and interlocking the package with a plurality of other lighting device packages to form a bundle of packaged lighting devices, wherein each of the lighting devices includes an encasing structure around its respective luminaire.
 17. The method of claim 16, wherein the bundle of lighting devices forms a structure having encased luminaires on two ends and light fixture poles in the center.
 18. The method of claim 17, wherein each of the encased luminaires at one end of the bundle is connected to a pole secured by the encasing structure of the luminaires at the other end of the bundle.
 19. The method of claim 17, further comprising placing each of the two ends of the bundle on a separate shipping pallet.
 20. A bundle of packaged lighting devices comprising: a first set of packaged lighting devices connected to one another; a second set packaged lighting devices connected to one another; wherein a luminaire of each lighting device is surrounded by an encasing structure and a pole of each lighting device extends from the encasing structure; and wherein the poles of the first set are secured to the second set and the poles of the second set are secured to the first set. 